Golf ball compositions

ABSTRACT

Disclosed herein are heterogeneous golf ball compositions comprising a thermosetting polymer matrix and discrete particles of thermoplastic polymer dispersed within the matrix.

FIELD OF THE INVENTION

The present invention is directed to golf ball compositions comprisingdiscrete particles of unmelted thermoplastic polymer within athermosetting polymer matrix.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 5,789,486 to Maruoka et al. discloses a golf ballincluding a paint layer comprised of a dispersion ofinternally-crosslinked polymer gel fine particles.

U.S. Pat. No. 6,186,906 to Sullivan et al. discloses golf ballcompositions comprising discrete particles of gel.

U.S. Pat. No. 7,402,114 to Binette et al. discloses golf ball materialscomprising a partially to highly neutralized blend of copolymers, afatty acid or fatty acid salt, and a heavy mass filler.

U.S. Pat. No. 7,612,135 to Kennedy, III et al. discloses golf ballmaterials comprising a partially to highly neutralized blend of an acidcopolymer, a copolymer comprising a metallocene-catalyzed alpha-olefinand a softening comonomer, and a fatty acid or fatty acid salt.

U.S. Patent Application Publication No. 2008/0234070 to Comeau et al.discloses the use of crosslinked rubber nanoparticles in golf balllayers.

U.S. Pat. No. 5,733,974 to Yamada et al. discloses a golf ballcomprising a core made of an elastomer and a cover covering said corewherein said cover is made of a thermoplastic material comprising arubber powder and a thermoplastic elastomer.

U.S. Pat. No. 6,465,573 to Maruko et al. discloses a solid golf ballcomprising a core, an intermediate layer, and a cover improved inrebound, distance, and feel when the intermediate layer is comprised ofa thermoplastic resin in admixture with rubber powder.

U.S. Pat. No. 5,779,561 to Sullivan et al. discloses a golf ballincluding an inner cover layer comprising (1) a first resin compositioncontaining at least 50 parts by weight of a non-ionomeric polyolefinmaterial and (2) at least one part by weight of a filler.

U.S. Patent Application Publication No. 2003/0216520 to Irii et al.discloses a golf ball whose core is covered with a cover, wherein thecore is constituted of a rubber composition containing polybutadienerubber and the cover is constituted of a resin composition composed ofionomer resin and diene rubber.

U.S. Patent Application Publication No. 2012/0165122 to Kim et al.discloses a golf ball where at least one of the outer cover layer andthe intermediate layer includes a blend composition of about 2 about 40wt % of a polyamide and about 60 to about 98 wt % of one or more ofeither a block copolymer, an acidic copolymer; an acidic terpolymer; anionomer, or a multi component blend composition; and wherein thepolyamide has a melting point which is greater than about 5 and lessthan about 200° C. above the melting point of the other blend component.

U.S. Pat. No. 6,361,453 to Nakamura et al. discloses a solid golf ballhaving a solid core and a cover, the solid core is composed of acore-forming material and particles of a different material.

SUMMARY OF THE INVENTION

The present invention is directed to golf balls comprising a layerformed from a heterogeneous composition. The heterogeneous compositioncomprises a matrix formed from a thermosetting polymer composition anddiscrete particles of a thermoplastic polymer composition dispersedwithin the matrix. The thermoplastic polymer composition has a meltingpoint above the curing temperature of the thermosetting polymercomposition.

In a particular embodiment, the particles have a maximum particle sizeof 0.900 mm.

In another particular embodiment, the difference in the specific gravityof the thermosetting polymer composition and the specific gravity of thethermoplastic composition is at least 0.13 g/cm³.

In another particular embodiment, the composition comprises at least 500of the discrete particles.

In another particular embodiment, the particles have a maximum particlesize of 0.900 mm and are present in the heterogeneous composition in anamount of 18 wt % or greater, based on the total weight of theheterogeneous composition, and the difference in the specific gravity ofthe thermosetting polymer composition and the specific gravity of thethermoplastic composition is at least 0.13 g/cm³.

DETAILED DESCRIPTION

Golf ball compositions of the present invention are heterogeneouscompositions comprising discrete unmelted thermoplastic particlesdispersed within a thermosetting polymer matrix. The thermoplasticparticle composition has a melting point above the curing temperature ofthe matrix composition such that the particles do not melt uponformation of the golf ball component formed from the heterogeneouscomposition.

In a particular embodiment, the difference in the specific gravity ofthe matrix composition and the specific gravity of the particlecomposition is at least 0.10 g/ cm³, or at least 0.11 g/cm³, or at least0.12 g/cm³, or at least 0.13 g/cm³, or at least 0.14 g/cm³, or at least0.15 g/cm³, or at least 0.16 g/cm³, or at least 0.17 g/cm³, or at least0.18 g/cm³, or at least 0.19 g/cm³, or at least 0.20 g/cm³.

The heterogeneous composition is formed by adding the particles to thematrix composition either prior to forming the golf ball layer or duringthe process of molding or casting the golf ball layer. In a particularembodiment, the heterogeneous composition has a solid sphere coefficientof restitution, “COR,” within a range having a lower limit of 0.450 or0.500 or 0.550 or 0.600 or 0.650 or 0.700 and an upper limit of 0.710 or0.730 or 0.750 or 0.770 or 0.800 or 0.820 or 0.850 or 0.870 or 0.900 or0.910 or 0.950. For purposes of the present disclosure, the “solidsphere COR” of a composition refers to the COR of a cured 1.55 inchdiameter sphere of the composition. COR is determined according to aknown procedure wherein a sphere is fired from an air cannon at twogiven velocities and calculated at a velocity of 125 ft/s. Ballisticlight screens are located between the air cannon and the steel plate ata fixed distance to measure sphere velocity. As the sphere travelstoward the steel plate, it activates each light screen, and the time ateach light screen is measured. This provides an incoming transit timeperiod inversely proportional to the sphere's incoming velocity. Thesphere impacts the steel plate and rebounds though the light screens,which again measures the time period required to transit between thelight screens. This provides an outgoing transit time period inverselyproportional to the sphere's outgoing velocity. COR is then calculatedas the ratio of the outgoing transit time period to the incoming transittime period, COR=V_(out)/V_(in)=T_(in)/T_(out).

In a particular embodiment, the heterogeneous composition has a solidsphere compression within a range having a lower limit of −75 or −50 or−20 or 0 or 10 or 15 and an upper limit of 20 or 25 or 30 or 35 or 40 or50. In another particular embodiment, the heterogeneous composition hasa solid sphere compression within a range having a lower limit of 70 or75 or 80 or 85 or 90 and an upper limit of 90 or 95 or 100 or 105 or 115or 120 or 125. In another particular embodiment, the heterogeneouscomposition has a solid sphere compression within a range having a lowerlimit of 120 or 130 or 140 or 150 or 155 or 160 and an upper limit of160 or 165 or 170 or 180 or 190 or 200. In another particularembodiment, the heterogeneous composition has a solid sphere compressionof 130 or greater, or 140 or greater, or 150 or greater, or 155 orgreater, or 160 or greater, or 165 or greater, or 170 or greater. Forpurposes of the present disclosure, the “solid sphere compression” of acomposition refers to the compression of a cured 1.55 inch diametersphere of the composition. The compression of the sphere is determinedaccording to a known procedure, using a digital Atti compression testdevice, wherein a piston is used to compress a ball against a spring.Conversion from Atti compression to Riehle (cores), Riehle (balls), 100kg deflection, 130-10 kg deflection or effective modulus can be carriedout according to the formulas given in Jeff Dalton's Compression by AnyOther Name, Science and Golf IV, Proceedings of the World ScientificCongress of Golf (Eric Thain ed., Routledge, 2002).

In a particular embodiment, the heterogeneous composition has a flexuralmodulus, as measured according to the method given in the Examplesbelow, of 5 ksi or greater, 6 ksi or greater, or 8 ksi or greater, or 10ksi or greater, or 15 ksi or greater, or 20 ksi or greater, or 25 ksi orgreater, or 30 ksi or greater, or 35 ksi or greater, or 40 ksi orgreater, or 45 ksi or greater, or 48 ksi or greater, or 50 ksi orgreater, or 52 ksi or greater, or 55 ksi or greater, or 60 ksi orgreater, or 63 ksi or greater, or 65 ksi or greater, or 70 ksi orgreater, 100 ksi or greater, or 120 ksi or greater, or 150 ksi orgreater, or 160 ksi or greater, or 170 ksi or greater, or 180 ksi orgreater, or 195 ksi or greater, or a flexural modulus within a rangehaving a lower limit of 5 or 6 or 8 or 10 or 15 or 20 or 25 or 30 or 35or 40 or 45 or 48 or 50 or 52 or 55 or 55 or 60 or 63 or 65 or 70 ksiand an upper limit of 75 or 80 or 85 or 90 or 95 or 100 or 105 or 110 or115 ksi, or a flexural modulus within a range having a lower limit of 20or 25 or 30 or 35 or 40 or 45 or 50 or 55 or 60 ksi and an upper limitof 60 or 65 or 70 or 75 or 80 ksi, or a flexural modulus within a rangehaving a lower limit of 50 or 60 or 70 or 90 or 120 or 130 and an upperlimit of 150 or 170 or 200 or 210.

In a particular embodiment, the particles are present in the compositionin an amount of 1 wt % or greater, or 2 wt % or greater, or 3 wt % orgreater, or 5 wt % or greater, or 10 wt % or greater, or 15 wt % orgreater, or 20 wt % or greater, or 25 wt % or greater, or 30 wt % orgreater, or 35 wt % or greater, or 40 wt % or greater, or 45 wt % orgreater, or 50 wt % or greater, or 55 wt % or greater, or 60 wt % orgreater, or an amount within a range having a lower limit of 1 or 2 or 3or 5 or 10 or 15 or 20 or 25 or 30 or 35 or 40 wt % and an upper limitof 50 or 55 or 60 or 65 or 70 or 75 or 80 or 85 or 90 wt %, based on thetotal weight of the composition.

In another particular embodiment, the composition comprises at least 500of the discrete particles.

In a particular embodiment, the particles have a maximum particle sizeof 0.595 mm or 0.707 mm or 0.841 mm or 0.900 mm or 1.00 mm or 1.19 mm or1.41 mm or 1.68 mm or 2.00 mm or 2.38 mm. In another embodiment, thecrosslinked particles have a particle size within a range having a lowerlimit of 0.001 mm or 0.002 mm or 0.005 mm or 0.007 mm or 0.015 mm or0.030 mm or 0.037 or mm or 0.074 mm and an upper limit of 0.100 mm or0.125 mm or 0.177 mm or 0.354 mm or 0.420 mm or 0.500 mm or 0.595 mm or0.707 mm or 0.841 mm 1.000 mm or 1.19 mm or 1.41 mm or 1.68 mm or 2.00mm or 2.38 mm.

Matrix Composition

Thermosetting compositions suitable for forming the matrix includenatural rubbers, polybutadienes, polyisoprenes, ethylene propylenerubbers (EPR), ethylene-propylene-diene rubbers (EPDM),styrene-butadiene rubbers, butyl rubbers, halobutyl rubbers,polyurethanes, polyureas, acrylonitrile butadiene rubbers,polychloroprenes, alkyl acrylate rubbers, chlorinated isoprene rubbers,acrylonitrile chlorinated isoprene rubbers, polyalkenamers, phenolformaldehydes, melamine formaldehydes, polyepoxides, polysiloxanes,polyesters, alkyds, polyisocyanurates, polycyanurates, polyacrylates,and combinations of two or more thereof.

Non-limiting examples of suitable commercially available thermosettingmaterials are Buna CB high-cis neodymium-catalyzed polybutadienerubbers, such as Buna CB 23, and Buna CB high-cis cobalt-catalyzedpolybutadiene rubbers, such as Buna CB 1220 and 1221, commerciallyavailable from Lanxess Corporation; SE BR-1220, commercially availablefrom The Dow Chemical Company; Europrene® NEOCIS® BR 40 and BR 60,commercially available from Polimeri Europa®; UBEPOL-BR® rubbers,commercially available from UBE Industries, Inc.; BR 01, commerciallyavailable from Japan Synthetic Rubber Co., Ltd.; Neodene high-cisneodymium-catalyzed polybutadiene rubbers, such as Neodene BR 40,commercially available from Karbochem; TP-301 transpolyisoprene,commercially available from Kuraray Co., Ltd.; Vestenamer®polyoctenamer, commercially available from Evonik Industries; Butyl 065and Butyl 288 butyl rubbers, commercially available from ExxonMobilChemical Company; Butyl 301 and Butyl 101-3, commercially available fromLanxess Corporation; Bromobutyl 2224 and Chlorobutyl 1066 halobutylrubbers, commercially available from ExxonMobil Chemical Company;Bromobutyl X2 and Chlorobutyl 1240 halobutyl rubbers, commerciallyavailable from Lanxess Corporation; BromoButyl 2255 butyl rubber,commercially available from Japan Synthetic Rubber Co., Ltd.; Vistalon®404 and Vistalon® 706 ethylene propylene rubbers, commercially availablefrom ExxonMobil Chemical Company; Dutral CO 058 ethylene propylenerubber, commercially available from Polimeri Europa; Nordel® IP NDR 5565and Nordel® IP 3670 ethylene-propylene-diene rubbers, commerciallyavailable from The Dow Chemical Company; EPT1045 and EPT1045ethylene-propylene-diene rubbers, commercially available from MitsuiCorporation; Buna SE 1721 TE styrene-butadiene rubbers, commerciallyavailable from Lanxess Corporation; Afpol 1500 and Afpol 552styrene-butadiene rubbers, commercially available from Karbochem; Nipol®DN407 and Nipol® 1041L acrylonitrile butadiene rubbers, commerciallyavailable from Zeon Chemicals, L.P.; Neoprene GRT and Neoprene AD30polychloroprene rubbers; Vamac® ethylene acrylic elastomers,commercially available from E. I. du Pont de Nemours and Company;Hytemp® AR12 and AR214 alkyl acrylate rubbers, commercially availablefrom Zeon Chemicals, L.P.; and Hypalon® chlorosulfonated polyethylenerubbers, commercially available from E. I. du Pont de Nemours andCompany.

The matrix composition may contain one or more fillers. Exemplaryfillers include precipitated hydrated silica, clay, talc, asbestos,glass fibers, aramid fibers, mica, calcium metasilicate, zinc sulfate,barium sulfate, zinc sulfide, lithopone, silicates, silicon carbide,diatomaceous earth, carbonates (e.g., calcium carbonate, zinc carbonate,barium carbonate, and magnesium carbonate), metals (e.g., titanium,tungsten, aluminum, bismuth, nickel, molybdenum, iron, lead, copper,boron, cobalt, beryllium, zinc, and tin), metal alloys (e.g., steel,brass, bronze, boron carbide whiskers, and tungsten carbide whiskers),oxides (e.g., zinc oxide, tin oxide, iron oxide, calcium oxide, aluminumoxide, titanium dioxide, magnesium oxide, and zirconium oxide),particulate carbonaceous materials (e.g., graphite, carbon black, cottonflock, natural bitumen, cellulose flock, and leather fiber),microballoons (e.g., glass and ceramic), fly ash, core material that isground and recycled, nanofillers and combinations thereof.

The matrix composition may also contain one or more additives selectedfrom processing aids, such as transpolyisoprene (e.g., TP-301transpolyisoprene, commercially available from Kuraray Co., Ltd.) andtransbutadiene rubber; processing oils; plasticizers; coloring agents;fluorescent agents; chemical blowing and foaming agents; defoamingagents; stabilizers; softening agents; impact modifiers; free radicalscavengers; accelerators; scorch retarders; and the like.

Suitable rubbers are more fully described in, for example, U.S. Pat.Nos. 6,566,483, 6,695,718, 6,939,907, 7,041,721 and 7,138,460, theentire disclosures of which are hereby incorporated herein by reference.Particularly suitable diene rubber compositions are further disclosed,for example, in U.S. Patent Application Publication No. 2007/0093318,the entire disclosure of which is hereby incorporated herein byreference.

Particle Composition

Particle compositions of the present invention are thermoplastic. Forpurposes of the present invention, thermoplastics do not includepolymers that degrade before they melt, such as poly-para-phenyleneterephthalamide (e.g., Kevlar° para-aramid fibers).

Suitable compositions for forming the dispersed particles are selectedfrom thermoplastic polymer compositions having a melting point above thecuring temperature of the matrix composition. Particular examples ofsuitable thermoplastic compositions for forming the particles includeionomers, non-ionomeric acid copolymers, polyesters, polyamides,polyether amides, polyester amides, polyimides, polyurethanes,polyureas, polystyrenes, polyethylenes, polypropylenes, rubber-toughenedpolyolefins, styrenic copolymers and styrenic block copolymers,dynamically vulcanized elastomers, ethylene vinyl acetates, ethylene(meth)acrylate based polymers, ethylene elastomers, propyleneelastomers, copolymers of ethylene and propylene, polyvinyl chlorides,polytetrafluoroethylene (e.g., Teflon® polytetrafluoroethylene,commercially available from E. I. du Pont de Nemours and Company),functionalized derivatives thereof, and combinations of two or morethereof.

Suitable ionomer compositions include partially neutralized ionomers andhighly neutralized ionomers, including ionomers formed from blends oftwo or more partially neutralized ionomers, blends of two or more highlyneutralized ionomers, and blends of one or more partially neutralizedionomers with one or more highly neutralized ionomers. Preferredionomers are salts of O/X- and O/X/Y-type acid copolymers, wherein O isan α-olefin, X is a C₃-C₈ α,β-ethylenically unsaturated carboxylic acid,and Y is a softening monomer. O is preferably selected from ethylene andpropylene. X is preferably selected from methacrylic acid, acrylic acid,ethacrylic acid, crotonic acid, and itaconic acid. Methacrylic acid andacrylic acid are particularly preferred. As used herein, “(meth) acrylicacid” means methacrylic acid and/or acrylic acid. Likewise, “(meth)acrylate” means methacrylate and/or acrylate. Y is preferably selectedfrom (meth) acrylate and alkyl (meth) acrylates wherein the alkyl groupshave from 1 to 8 carbon atoms, including, but not limited to, n-butyl(meth) acrylate, isobutyl (meth) acrylate, methyl (meth) acrylate, andethyl (meth) acrylate. Particularly preferred O/X/Y-type copolymers areethylene/(meth) acrylic acid/n-butyl (meth) acrylate, ethylene/(meth)acrylic acid/isobutyl (meth) acrylate, ethylene/(meth) acrylicacid/methyl (meth) acrylate, and ethylene/(meth) acrylic acid/ethyl(meth) acrylate. The acid is typically present in the acid copolymer inan amount of 6 wt % or greater, or 9 wt % or greater, or 10 wt % orgreater, or 11 wt % or greater, or 15 wt % or greater, or 16 wt % orgreater, or in an amount within a range having a lower limit of 1 or 4or 6 or 8 or 10 or 11 or 12 or 15 wt % and an upper limit of 15 or 16 or17 or 19 or 20 or 20.5 or 21 or 25 or 30 or 35 or 40 wt %, based on thetotal weight of the acid copolymer. The acid copolymer is at leastpartially neutralized with a cation source, optionally in the presenceof a high molecular weight organic acid, such as those disclosed in U.S.Pat. No. 6,756,436, the entire disclosure of which is herebyincorporated herein by reference. Suitable cation sources include, butare not limited to, metal ion sources, such as compounds of alkalimetals, alkaline earth metals, transition metals, and rare earthelements; ammonium salts and monoamine salts; and combinations thereof.Preferred cation sources are compounds of magnesium, sodium, potassium,cesium, calcium, barium, manganese, copper, zinc, tin, lithium, and rareearth metals. Suitable ionomers are further disclosed, for example, inU.S. Patent Application Publication Nos. 2005/0049367, 2005/0148725,2005/0020741, 2004/0220343, and 2003/0130434, and U.S. Pat. Nos.5,587,430, 5,691,418, 5,866,658, 6,100,321, 6,562,906, 6,653,382,6,777,472, 6,762,246, 6,815,480, and 6,953,820, the entire disclosuresof which are hereby incorporated herein by reference.

Non-limiting examples of suitable commercially available thermoplasticsare Surlyn® ionomers and DuPont® HPF 1000 and HPF 2000 highlyneutralized ionomers, commercially available from E. I. du Pont deNemours and Company; Clarix® ionomers, commercially available from A.Schulman, Inc.; Iotek® ionomers, commercially available from ExxonMobilChemical Company; Amplify® IO ionomers, commercially available from TheDow Chemical Company; Amplify® GR functional polymers and Amplify® TYfunctional polymers, commercially available from The Dow ChemicalCompany; Fusabond® functionalized polymers, including ethylene vinylacetates, polyethylenes, metallocene-catalyzed polyethylenes, ethylenepropylene rubbers, and polypropylenes, commercially available from E. I.du Pont de Nemours and Company; Exxelor® maleic anhydride graftedpolymers, including high density polyethylene, polypropylene,semi-crystalline ethylene copolymer, amorphous ethylene copolymer,commercially available from ExxonMobil Chemical Company; ExxonMobil® PPseries polypropylene impact copolymers, such as PP7032E3, PP7032KN,PP7033E3, PP7684KN, commercially available from ExxonMobil ChemicalCompany; Vistamaxx® propylene-based elastomers, commercially availablefrom ExxonMobil Chemical Company; Vistalon® EPDM rubbers, commerciallyavailable from ExxonMobil Chemical Company; Exact® plastomers,commercially available from ExxonMobil Chemical Company; Santoprene®thermoplastic vulcanized elastomers, commercially available fromExxonMobil Chemical Company; Nucrel® acid copolymers, commerciallyavailable from E. I. du Pont de Nemours and Company; Escor® acidcopolymers, commercially available from ExxonMobil Chemical Company;Primacor® acid copolymers, commercially available from The Dow ChemicalCompany; Kraton® styrenic block copolymers, commercially available fromKraton Performance Polymers Inc.; Septon® styrenic block copolymers,commercially available from Kuraray Co., Ltd.; Lotader® ethyleneacrylate based polymers, commercially available from Arkema Corporation;Polybond® grafted polyethylenes and polypropylenes, commerciallyavailable from Chemtura Corporation; Royaltuf® chemically modified EPDM,commercially available from Chemtura Corporation; Vestenamer®polyoctenamer, commercially available from Evonik Industries; Pebax®polyether and polyester amides, commercially available from Arkema Inc.;polyester-based thermoplastic elastomers, such as Hytrel® polyesterelastomers, commercially available from E. I. du Pont de Nemours andCompany, and Riteflex® polyester elastomers, commercially available fromTicona; Estane® thermoplastic polyurethanes, commercially available fromThe Lubrizol Corporation; Grivory® polyamides and Grilamid® polyamides,commercially available from EMS Grivory; Zytel® polyamide resins andElvamide® nylon multipolymer resins, commercially available from E. I.du Pont de Nemours and Company; and Elvaloy® acrylate copolymer resins,commercially available from E. I. du Pont de Nemours and Company.

In a particular embodiment, the particle composition is formed from ablend of at least two different polymers. In a particular aspect of thisembodiment, at least one polymer is an ionomer.

In another particular embodiment, the particle composition is formedfrom a blend of at least a first and a second ionomer.

In another particular embodiment, the particle composition is formedfrom a blend of one or more ionomers and one or more additional polymersselected from non-ionomeric polyolefins, polyesters, polyamides,polyurethanes, polystyrenes, and functionalized derivatives thereof.

In another particular embodiment, the particle composition is formedfrom a blend of at least a functionalized polyethylene and afunctionalized polymer selected from polyethylenes, includingmetallocene-catalyzed and non-metallocene-catalyzed polyethylenes,ethylene vinyl acetates, ethylene acid copolymers, ethylene(meth)acrylate copolymers, ethylene elastomers, and polypropylenes. In aparticular aspect of this embodiment, the functionalized polyethylene isa maleic anhydride-grafted polymer selected from ethylene homopolymers,ethylene-hexene copolymers, ethylene-octene copolymers, andethylene-butene copolymers.

In another particular embodiment, the particle composition is formedfrom a blend of at least an ionomer, a functionalized polyethylene and afunctionalized polymer selected from polyethylenes, includingmetallocene-catalyzed and non-metallocene-catalyzed polyethylenes,ethylene vinyl acetates, ethylene acid copolymers, ethylene(meth)acrylate copolymers, ethylene elastomers, and polypropylenes. In aparticular aspect of this embodiment, the functionalized polyethylene isa maleic anhydride-grafted polymer selected from ethylene homopolymers,ethylene-hexene copolymers, ethylene-octene copolymers, andethylene-butene copolymers.

In another particular embodiment, the particle composition is formedfrom a blend of at least an ionomer and a maleic anhydride-graftedpolyethylene. In a particular aspect of this embodiment, thepolyethylene is selected from ethylene homopolymers, ethylene-hexenecopolymers, ethylene-octene copolymers, and ethylene-butene copolymers.

In another particular embodiment, the particle composition is formedfrom a blend of at least an ionomer and a functionalized polymerselected from polyethylenes, including metallocene-catalyzed andnon-metallocene-catalyzed polyethylenes, ethylene vinyl acetates,ethylene acid copolymers, ethylene elastomers, and polypropylenes.

In another particular embodiment, the particle composition is formedfrom a blend of at least an ionomer and an acid copolymer.

In another particular embodiment, the particle composition is formedfrom a blend of at least an ionomer and a styrenic block copolymer orfunctionalized derivative thereof.

In another particular embodiment, the particle composition is formedfrom a blend of at least an ionomer and an ethylene (meth)acrylate basedpolymer or functionalized derivative thereof.

In another particular embodiment, the particle composition is formedfrom a blend of at least an ionomer and an EPDM or functionalizedderivative thereof.

In another particular embodiment, the particle composition is formedfrom a blend of at least an ionomer and a polyoctenamer or afunctionalized derivative thereof.

In another particular embodiment, the particle composition includes atleast an ionomer, wherein the ionomer is a partially- or highly-neutralized very low acid ethylene copolymer.

In another particular embodiment, the particle composition is formedfrom a blend including at least a functionalized ethylene homopolymer orcopolymer, including, but not limited to, functionalized ethylene(meth)acrylate copolymers, particularly, glycidyl methacrylate-graftedpolyethylenes and glycidyl methacrylate-grafted ethylene/n-butylacrylate copolymers.

In another particular embodiment, the particle composition is formedfrom a blend including at least an ionomer and a thermoplasticpolyurethane. In a particular aspect of this embodiment, thepolyurethane is selected from the polyurethanes disclosed in U.S. PatentApplication Publication No. 2005/0256294, the entire disclosure of whichis hereby incorporated herein by reference.

In another particular embodiment, the particle composition is formedfrom a blend including:

-   -   (a) a first component selected from polyester elastomers (e.g.,        Hytrel® polyester elastomers, commercially available from E. I.        du Pont de Nemours and Company, and Riteflex® polyester        elastomers, commercially available from Ticona); polyether block        amides (e.g., Pebax® polyether and polyester amides);        polyester-ether amides; and polypropylene ether glycol        compositions, such as those disclosed, e.g., in U.S. Patent        Application Publication No. 2005/0256294, the entire disclosure        of which is hereby incorporated herein by reference; and        combinations of two or more thereof;    -   (b) a second component selected from O/X/Y-type ionomers,        including partially and highly-neutralized ionomers,        particularly highly neutralized ionomers comprising fatty acid        salts, such as DuPont® HPF 1000 and HPF 2000 highly neutralized        ionomers, and VLMI-type ionomers, such as Surlyn® 9320 ionomer;        O/X/Y-type acid copolymers; and polyamides and polyamide blends,        particularly selected from the polyamides and polyamide blends        disclosed above.

In a particular aspect of this embodiment, the particle composition isformed from a blend including at least a polyester elastomer and ahighly neutralized ionomer comprising fatty acid salts. Such blend isdisclosed, for example, in U.S. Pat. No. 7,375,151, the entiredisclosure of which is hereby incorporated herein by reference.

In another particular embodiment, the particle composition is formedfrom a blend including at least a polyester, an ionomer, and a graftedEPDM. Such blends are further disclosed, for example, in U.S. Pat. No.4,303,573, the entire disclosure of which is hereby incorporated hereinby reference.

In another particular embodiment, the particle composition is anon-halogenated thermoplastic polymer composition.

In another particular embodiment, the particle composition is anon-chlorinated thermoplastic polymer composition. In a particularaspect of this embodiment, the particle composition does not comprise apolyvinyl chloride.

In another particular embodiment, the particle composition is selectedfrom polycarbonates, polyamides, and polyether and polyester amides(e.g., Pebax® thermoplastic polyether and polyester amides). In anotherparticular embodiment, the particle composition does not includepolyamide.

In a particular embodiment, the particle composition comprises a basepolymer, the base polymer having a specific gravity of 1.40 g/cm³ orless, or less than 1.40 g/cm³, or 1.38 g/cm³ or less, or less than 1.38g/cm³, or 1.35 g/cm³ or less, or less than 1.30 g/cm³, or 1.31 g/cm³ orless, or 1.30 g/cm³ or less, or 1.25 g/cm³ or less, or 1.20 g/cm³ orless, or 1.15 g/cm³ or less, or 1.10 g/cm³ or less. In anotherparticular embodiment, the particle composition comprises a basepolymer, the base polymer having a specific gravity of 1.40 g/cm³ orgreater, or greater than 1.40 g/cm³, or 1.41 g/cm³ or greater, orgreater than 1.41 g/cm³, or 1.42 g/cm³ or greater, or greater than 1.42g/cm³, or 1.43 g/cm³ or greater, or 1.44 g/cm³ or greater, or 1.45 g/cm³or greater, or greater than 1.45 g/cm³, or 1.46 g/cm³ or greater, or1.47 g/cm³ or greater, or 1.50 g/cm³ or greater, or greater than 1.50g/cm³, or 1.55 g/cm³ or greater, or 1.60 g/cm³ or greater, or greaterthan 1.60 g/cm³, or 1.70 g/cm³ or greater, or 1.75 g/cm³ or greater, or1.80 g/cm³ or greater.

The particle composition optionally includes additive(s) and/orfiller(s) in an amount of 50 wt % or less, or 30 wt % or less, or 20 wt% or less, or 15 wt % or less, based on the total weight of the matrixcomposition. Suitable additives and fillers include, but are not limitedto, chemical blowing and foaming agents, optical brighteners, coloringagents, fluorescent agents, whitening agents, UV absorbers, lightstabilizers, defoaming agents, processing aids, antioxidants,stabilizers, softening agents, fragrance components, plasticizers,impact modifiers, TiO₂, acid copolymer wax, surfactants, performanceadditives (e.g., A-C® performance additives, particularly A-C® lowmolecular weight ionomers and copolymers, A-C® oxidized polyethylenes,and A-C® ethylene vinyl acetate waxes, commercially available fromHoneywell International Inc.), fatty acid amides (e.g., ethylenebis-stearamide and ethylene bis-oleamide), fatty acids and salts thereof(e.g., stearic acid, oleic acid, zinc stearate, magnesium stearate, zincoleate, and magnesium oleate), and fillers, such as zinc oxide, tinoxide, barium sulfate, zinc sulfate, calcium oxide, calcium carbonate,zinc carbonate, barium carbonate, tungsten, tungsten carbide, silica,lead silicate, clay, mica, talc, nano-fillers, carbon black, glassflake, milled glass, flock, fibers, and mixtures thereof. Suitableadditives are more fully described in, for example, U.S. PatentApplication Publication No. 2003/0225197, the entire disclosure of whichis hereby incorporated herein by reference. In a particular embodiment,the total amount of additive(s) and filler(s) present in the particlecomposition is 20 wt % or less, or 15 wt % or less, or 12 wt % or less,or 10 wt % or less, or 9 wt % or less, or 6 wt % or less, or 5 wt % orless, or 4 wt % or less, or 3 wt % or less, or within a range having alower limit of 0 or 2 or 3 or 5 wt %, based on the total weight of theparticle composition, and an upper limit of 9 or 10 or 12 or 15 or 20 wt%, based on the total weight of the particle composition. In aparticular aspect of this embodiment, the particle composition includesfiller(s) selected from carbon black, micro- and nano-scale clays andorganoclays, including (e.g., Cloisite® and Nanofil® nanoclays,commercially available from Southern Clay Products, Inc.; Nanomax® andNanomer® nanoclays, commercially available from Nanocor, Inc., andPerkalite® nanoclays, commercially available from Akzo Nobel PolymerChemicals), micro- and nano-scale talcs (e.g., Luzenac HAR® high aspectratio talcs, commercially available from Luzenac America, Inc.), glass(e.g., glass flake, milled glass, microglass, and glass fibers), micro-and nano-scale mica and mica-based pigments (e.g., Iriodin® pearl lusterpigments, commercially available from The Merck Group), and combinationsthereof. Particularly suitable combinations of fillers include, but arenot limited to, micro-scale filler(s) combined with nano-scalefiller(s), and organic filler(s) with inorganic filler(s).

The particle composition optionally includes one or more melt flowmodifiers. Suitable melt flow modifiers include materials which increasethe melt flow of the composition, as measured using ASTM D-1238,condition E, at 190° C., using a 2160 gram weight. Examples of suitablemelt flow modifiers include, but are not limited to, fatty acids andfatty acid salts, including, but not limited to, those disclosed in U.S.Pat. No. 5,306,760, the entire disclosure of which is herebyincorporated herein by reference; fatty amides and salts thereof;polyhydric alcohols, including, but not limited to, those disclosed inU.S. Pat. No. 7,365,128, and U.S. Patent Application Publication No.2010/0099514, the entire disclosures of which are hereby incorporatedherein by reference; polylactic acids, including, but not limited to,those disclosed in U.S. Pat. No. 7,642,319, the entire disclosure ofwhich is hereby incorporated herein by reference; and the modifiersdisclosed in U.S. Patent Application Publication No. 2010/0099514 and2009/0203469, the entire disclosures of which are hereby incorporatedherein by reference. Flow enhancing additives also include, but are notlimited to, montanic acids, esters of montanic acids and salts thereof,bis-stearoylethylenediamine, mono- and polyalcohol esters such aspentaerythritol tetrastearate, zwitterionic compounds, andmetallocene-catalyzed polyethylene and polypropylene wax, includingmaleic anhydride modified versions thereof, amide waxes and alkylenediamides such as bistearamides. Particularly suitable fatty amidesinclude, but are not limited to, saturated fatty acid monoamides (e.g.,lauramide, palmitamide, arachidamide behenamide, stearamide, and12-hydroxy stearamide); unsaturated fatty acid monoamides (e.g.,oleamide, erucamide, and ricinoleamide); N-substituted fatty acid amides(e.g., N-stearyl stearamide, N-behenyl behenamide, N-stearyl behenamide,N-behenyl stearamide, N-oleyl oleamide, N-oleyl stearamide, N-stearyloleamide, N-stearyl erucamide, erucyl erucamide, and erucyl stearamide,N-oleyl palmitamide, methylol amide (more preferably, methylolstearamide, methylol behenamide); saturated fatty acid bis-amides (e.g.,methylene bis-stearamide, ethylene bis-stearamide, ethylenebis-isostearamide, ethylene bis-hydroxystearamide, ethylenebis-behenamide, hexamethylene bis-stearamide, hexamethylenebis-behenamide, hexamethylene bis-hydroxystearamide, N,N′-distearyladipamide, and N,N′-distearyl sebacamide); unsaturated fatty acidbis-amides (e.g., ethylene bis-oleamide, hexamethylene bis-oleamide,N,N′-dioleyl adipamide, N,N′-dioleyl sebacamide); and saturated andunsaturated fatty acid tetra amides, stearyl erucamide, ethylene bisstearamide and ethylene bis oleamide. Suitable examples of commerciallyavailable fatty amides include, but are not limited to, Kemamide® fattyacids, such as Kemamide® B (behenamide/arachidamide), Kemamide® W40(N,N′-ethylenebisstearamide), Kemamide® P181 (oleyl palmitamide),Kemamide® S (stearamide), Kemamide® U (oleamide), Kemamide® E(erucamide), Kemamide® O (oleamide), Kemamide® W45(N,N′-ethylenebisstearamide), Kenamide® W20 (N,N′-ethylenebisoleamide),Kemamide® E180 (stearyl erucamide), Kemamide® E221 (erucyl erucamide),Kemamide® S180 (stearyl stearamide), Kemamide® S221 (erucyl stearamide),commercially available from Chemtura Corporation; and Crodamide® fattyamides, such as Crodamide® OR (oleamide), Crodamide® ER (erucamide),Crodamide® SR (stereamide), Crodamide® BR (behenamide), Crodamide® 203(oleyl palmitamide), and Crodamide® 212 (stearyl erucamide),commercially available from Croda Universal Ltd.

In a particular embodiment, the particle composition has a Shore Dhardness within a limit having a lower limit of 20 or 30 or 35 or 45 andan upper limit of 55 or 60 or 65 or 70 or 75 or 80 or 85 or 90 or 95, ora Shore D hardness of 65 or greater, or 70 or greater, or 75 or greater,or 80 or greater, or 90 or greater.

Golf Ball Applications

Golf ball compositions according to the present invention can be used ina variety of constructions. For example, the compositions are suitablefor use in one-piece, two-piece (i.e., a core and a cover), multi-layer(i.e., a core of one or more layers and a cover of one or more layers),and wound golf balls, having a variety of core structures, intermediatelayers, covers, and coatings.

In golf balls of the present invention, at least one layer comprises aheterogeneous composition comprising discrete unmelted thermoplasticparticles dispersed within a thermosetting matrix, as described herein.In golf balls having two or more layers comprising a composition of thepresent invention, the inventive composition of one layer may be thesame as or a different inventive composition than another layer. Thelayer(s) comprising a composition of the present invention can be anyone or more of a core layer, an intermediate layer, or a cover layer.

Core Layer(s)

Cores of the golf balls formed according to the invention may be solid,semi-solid, hollow, fluid-, powder-, or gas-filled, and may be one-pieceor multi-layered. Multilayer cores include a center, innermost portion,which may be solid, semi-solid, hollow, fluid-, powder-, or gas-filled,surrounded by at least one outer core layer. The outer core layer may besolid, or it may be a wound layer formed of a tensioned elastomericmaterial. For purposes of the present disclosure, the term “semi-solid”refers to a paste, a gel, or the like.

In a particular embodiment, the present invention provides a golf ballhaving an innermost core layer formed from a heterogeneous compositionof the present invention. In another particular embodiment, the presentinvention provides a golf ball having an outer core layer formed from aheterogeneous composition of the present invention. In anotherparticular embodiment, the present invention provides a golf ball havingan intermediate core layer formed from a heterogeneous composition ofthe present invention.

Golf ball cores of the present invention may include one or more layersformed from a suitable material other than a heterogeneous compositionof the present invention. Suitable core materials include, but are notlimited to, thermoset materials, such as styrene butadiene rubber,polybutadiene, synthetic or natural polyisoprene, andtrans-polyisoprene; thermoplastics, such as ionomer resins, polyamidesand polyesters; and thermoplastic and thermoset polyurethane andpolyureas.

Intermediate Layer(s)

When the golf ball of the present invention includes one or moreintermediate layers, i.e., layer(s) disposed between the core and thecover of a golf ball, each intermediate layer can include any materialsknown to those of ordinary skill in the art including thermoplastic andthermosetting materials.

In one embodiment, the present invention provides a golf ball having anintermediate layer formed from a heterogeneous composition of thepresent invention.

Also suitable for forming intermediate layer(s) are the compositionsdisclosed above for forming core layers.

A moisture vapor barrier layer is optionally employed between the coreand the cover. Moisture vapor barrier layers are further disclosed, forexample, in U.S. Pat. Nos. 6,632,147, 6,838,028, 6,932,720, 7,004,854,and 7,182,702, and U.S. Patent Application Publication Nos.2003/0069082, 2003/0069085, 2003/0130062, 2004/0147344, 2004/0185963,2006/0068938, 2006/0128505 and 2007/0129172, the entire disclosures ofwhich are hereby incorporated herein by reference.

Cover

Golf ball covers of the present invention include single, dual, andmultilayer covers. Dual and multilayer covers have an inner cover layerand an outer cover layer, and multilayer covers additionally have atleast one intermediate cover layer disposed between the inner coverlayer and the outer cover layer.

In a particular embodiment, the present invention provides a golf ballhaving an outermost cover layer formed from a heterogeneous compositionof the present invention. In another particular embodiment, the presentinvention provides a golf ball having an inner cover layer formed from aheterogeneous composition of the present invention. In anotherparticular embodiment, the present invention provides a golf ball havingan intermediate cover layer formed from a heterogeneous composition ofthe present invention.

Golf ball covers of the present invention may include one or more layersformed from a suitable material other than a heterogeneous compositionof the present invention. The cover material is preferably a tough,cut-resistant material, selected based on the desired performancecharacteristics. Suitable cover materials for the golf balls disclosedherein include, but are not limited to, polyurethanes, polyureas, andhybrids of polyurethane and polyurea; ionomer resins and blends thereof(e.g., Surlyn® ionomer resins and DuPont® HPF 1000 and HPF 2000 highlyneutralized ionomers, commercially available from E. I. du Pont deNemours and Company; Iotek® ionomers, commercially available fromExxonMobil Chemical Company; Amplify® IO ionomers of ethylene acrylicacid copolymers, commercially available from The Dow Chemical Company;and Clarix® ionomer resins, commercially available from A. SchulmanInc.); polyisoprene; polyoctenamer, such as Vestenamer® polyoctenamer,commercially available from Evonik Industries; polyethylene, including,for example, low density polyethylene, linear low density polyethylene,and high density polyethylene; polypropylene; rubber-toughened olefinpolymers; non-ionomeric acid copolymers, e.g., ethylene (meth)acrylicacid; plastomers; flexomers; styrene/butadiene/styrene block copolymers;polybutadiene; styrene butadiene rubber; ethylene propylene rubber;ethylene propylene diene rubber; styrene/ethylene-butylene/styrene blockcopolymers; dynamically vulcanized elastomers; ethylene vinyl acetates;ethylene (meth)acrylates; polyvinyl chloride resins; polyamides,amide-ester elastomers, and copolymers of ionomer and polyamide,including, for example, Pebax® thermoplastic polyether and polyesteramides, commercially available from Arkema Inc; crosslinkedtrans-polyisoprene and blends thereof; polyester-based thermoplasticelastomers, such as Hytrel® polyester elastomers, commercially availablefrom E. I. du Pont de Nemours and Company, and Riteflex® polyesterelastomers, commercially available from Ticona; polyurethane-basedthermoplastic elastomers, such as Elastollan®, commercially availablefrom BASF; synthetic or natural vulcanized rubber; and combinationsthereof.

Polyurethanes, polyureas, and polyurethane-polyurea hybrids (i.e.,blends and copolymers of polyurethanes and polyureas) are particularlysuitable for forming cover layers of the present invention. Suitablepolyurethanes and polyureas are further disclosed, for example, in U.S.Pat. Nos. 5,334,673, 5,484,870, 6,506,851, 6,756,436, 6,835,794,6,867,279, 6,960,630, and 7,105,623; U.S. Patent Application PublicationNo. 2009/0011868; and U.S. Patent Application No. 60/401,047, the entiredisclosures of which are hereby incorporated herein by reference.Suitable polyurethane-urea cover materials include polyurethane/polyureablends and copolymers comprising urethane and urea segments, asdisclosed in U.S. Patent Application Publication No. 2007/0117923, theentire disclosure of which is hereby incorporated herein by reference.

Compositions comprising an ionomer or a blend of two or more ionomersare also particularly suitable for forming cover layers. Preferredionomeric cover compositions include:

-   -   (a) a composition comprising a “high acid ionomer” (i.e., having        an acid content of greater than 16 wt %), such as Surlyn® 8150;    -   (b) a composition comprising a high acid ionomer and a maleic        anhydride-grafted non-ionomeric polymer (e.g., Fusabond®        functionalized polymers). A particularly preferred blend of high        acid ionomer and maleic anhydride-grafted polymer is a 84 wt        %/16 wt % blend of Surlyn® 8150 and Fusabond®. Blends of high        acid ionomers with maleic anhydride-grafted polymers are further        disclosed, for example, in U.S. Pat. Nos. 6,992,135 and        6,677,401, the entire disclosures of which are hereby        incorporated herein by reference;    -   (c) a composition comprising a 50/45/5 blend of Surlyn®        8940/Surlyn® 9650/Nucrel® 960, preferably having a material        hardness of from 80 to 85 Shore C;    -   (d) a composition comprising a 50/25/25 blend of Surlyn®        8940/Surlyn® 9650/Surlyn® 9910, preferably having a material        hardness of about 90 Shore C;    -   (e) a composition comprising a 50/50 blend of Surlyn®        8940/Surlyn® 9650, preferably having a material hardness of        about 86 Shore C;    -   (f) a composition comprising a blend of Surlyn® 7940/Surlyn®        8940, optionally including a melt flow modifier;    -   (g) a composition comprising a blend of a first high acid        ionomer and a second high acid ionomer, wherein the first high        acid ionomer is neutralized with a different cation than the        second high acid ionomer (e.g., 50/50 blend of Surlyn® 8150 and        Surlyn® 9150), optionally including one or more melt flow        modifiers such as an ionomer, ethylene-acid polymer or ester        polymer; and    -   (h) a composition comprising a blend of a first high acid        ionomer and a second high acid ionomer, wherein the first high        acid ionomer is neutralized with a different cation than the        second high acid ionomer, and from 0 to 10 wt % of an        ethylene/acid/ester ionomer wherein the ethylene/acid/ester        ionomer is neutralized with the same cation as either the first        high acid ionomer or the second high acid ionomer or a different        cation than the first and second high acid ionomers (e.g., a        blend of 40-50 wt % Surlyn® 8150, 40-50 wt % Surlyn® 9120, and        0-10 wt % Surlyn® 6320).

Surlyn 8150® and Surlyn® 8940 are different grades of E/MAA copolymer inwhich the acid groups have been partially neutralized with sodium ions.Surlyn® 9650, Surlyn® 9910, Surlyn® 9150, and Surlyn® 9120 are differentgrades of E/MAA copolymer in which the acid groups have been partiallyneutralized with zinc ions. Surlyn® 7940 is an E/MAA copolymer in whichthe acid groups have been partially neutralized with lithium ions.Surlyn® 6320 is a very low modulus magnesium ionomer with a medium acidcontent. Nucrel® 960 is an E/MAA copolymer resin nominally made with 15wt % methacrylic acid. Surlyn® ionomers, Fusabond® polymers, and Nucrel®copolymers are commercially available from E. I. du Pont de Nemours andCompany.

Ionomeric cover compositions can be blended with non-ionic thermoplasticresins, such as polyurethane, poly-ether-ester, poly-amide-ether,polyether-urea, thermoplastic polyether block amides (e.g., Pebax®polyether and polyester amides, commercially available from ArkemaInc.), styrene-butadiene-styrene block copolymers,styrene(ethylene-butylene)-styrene block copolymers, polyamides,polyesters, polyolefins (e.g., polyethylene, polypropylene,ethylene-propylene copolymers, polyethylene-(meth)acrylate,polyethylene-(meth)acrylic acid, functionalized polymers with maleicanhydride grafting, Fusabond® functionalized polymers commerciallyavailable from E. I. du Pont de Nemours and Company, functionalizedpolymers with epoxidation, elastomers (e.g., ethylene propylene dienemonomer rubber, metallocene-catalyzed polyolefin) and ground powders ofthermoset elastomers.

Ionomer golf ball cover compositions may include a flow modifier, suchas, but not limited to, acid copolymer resins (e.g., Nucrel® acidcopolymer resins, and particularly Nucrel® 960, commercially availablefrom E. I. du Pont de Nemours and Company), performance additives (e.g.,A-C® performance additives, particularly A-C® low molecular weightionomers and copolymers, A-C® oxidized polyethylenes, and A-C® ethylenevinyl acetate waxes, commercially available from Honeywell InternationalInc.), fatty acid amides (e.g., ethylene bis-stearamide and ethylenebis-oleamide), fatty acids and salts thereof

Suitable ionomeric cover materials are further disclosed, for example,in U.S. Pat. Nos. 6,653,382, 6,756,436, 6,894,098, 6,919,393, and6,953,820, the entire disclosures of which are hereby incorporated byreference.

Suitable cover materials and constructions also include, but are notlimited to, those disclosed in U.S. Patent Application Publication No.2005/0164810, U.S. Pat. Nos. 5,919,100, 6,117,025, 6,767,940, and6,960,630, and PCT Publications WO00/23519 and WO00/29129, the entiredisclosures of which are hereby incorporated herein by reference.

Component Dimensions

Dimensions of golf ball components, i.e., thickness and diameter, mayvary depending on the desired properties. For the purposes of theinvention, any layer thickness may be employed.

The present invention relates to golf balls of any size. While USGAspecifications limit the size of a competition golf ball to more than1.68 inches in diameter, golf balls of any size can be used for leisuregolf play. The preferred diameter of the golf balls is from about 1.68inches to about 1.8 inches. The more preferred diameter is from about1.68 inches to about 1.76 inches. A diameter of from about 1.68 inchesto about 1.74 inches is most preferred, however diameters anywhere inthe range of from 1.7 to about 1.95 inches can be used.

Golf ball cores of the present invention include single, dual, andmultilayer cores, and preferably have an overall diameter within therange having a lower limit of 0.75 inches or 1 inch or 1.25 inches or1.4 inches and an upper limit of 1.55 inches or 1.6 inches or 1.62inches or 1.63 inches. In a particular embodiment, the golf ballcomprises a core and a cover, wherein the core is a solid, single layerhaving a diameter within a range having a lower limit of 0.750 or 1.00or 1.10 or 1.15 or 1.20 or 1.25 or 1.30 or 1.40 or 1.50 or 1.53 or 1.55inches and an upper limit of 1.55 or 1.60 or 1.62 or 1.63 or 1.65inches. In another particular embodiment, the golf ball comprises a coreand a cover, wherein the core comprises an inner core layer and an outercore layer, the inner core layer having a diameter within a range havinga lower limit of 0.500 or 0.750 or 0.900 or 0.950 or 1.000 inches and anupper limit of 1.100 or 1.200 or 1.250 or 1.400 or 1.550 or 1.570 or1.580 inches, and the outer core having a thickness within the rangehaving a lower limit of 0.020 or 0.025 or 0.032 or 0.050 or 0.100 or0.200 inches and an upper limit of 0.310 or 0.440 or 0.500 or 0.560 or0.800 inches.

When present in a golf ball of the present invention, each intermediatelayer has a thickness within a range having a lower limit of 0.002 or0.010 or 0.020 or 0.025 or 0.030 inches and an upper limit of 0.035 or0.040 or 0.045 or 0.050 or 0.060 or 0.090 or 0.100 or 0.150 or 0.200inches. The total thickness of intermediate core layer(s) in golf ballsof the present invention is preferably within the range having a lowerlimit of 0.020 or 0.0250 or 0.032 inches and an upper limit of 0.150 or0.220 or 0.28 inches.

Golf ball covers of the present invention include single, dual, andmultilayer covers, and preferably have an overall thickness within therange having a lower limit of 0.01 inches or 0.02 inches or 0.025 inchesor 0.03 inches or 0.04 inches or 0.045 inches or 0.05 inches or 0.06inches and an upper limit of 0.07 inches or 0.075 inches or 0.08 inchesor 0.09 inches or 0.1 inches or 0.15 inches or 0.2 inches or 0.3 inchesor 0.5 inches. Dual and multilayer covers have an inner cover layer andan outer cover layer, and multilayer covers additionally have at leastone intermediate cover layer disposed between the inner cover layer andthe outer cover layer. In a particular embodiment, the cover is a singlelayer having a thickness within a range having a lower limit of 0.020 or0.025 or 0.030 inches and an upper limit of 0.030 or 0.040 or 0.045 or0.050 or 0.070 or 0.100 or 0.120 or 0.150 or 0.350 or 0.400 or inches.In another particular embodiment, the cover comprises an inner coverlayer and an outer cover layer, the inner cover having a thicknesswithin a range having a lower limit of 0.010 or 0.020 or 0.025 or 0.030inches and an upper limit of 0.035 or 0.040 or 0.050 or 0.150 or 0.200inches, and the outer cover having a thickness within a range having alower limit of 0.010 or 0.020 or 0.025 or 0.030 inches and an upperlimit of 0.035 or 0.040 or 0.050 inches.

The golf balls of the present invention may be painted, coated, orsurface treated for further benefits.

When numerical lower limits and numerical upper limits are set forthherein, it is contemplated that any combination of these values may beused.

All patents, publications, test procedures, and other references citedherein, including priority documents, are fully incorporated byreference to the extent such disclosure is not inconsistent with thisinvention and for all jurisdictions in which such incorporation ispermitted.

While the illustrative embodiments of the invention have been describedwith particularity, it will be understood that various othermodifications will be apparent to and can be readily made by those ofordinary skill in the art without departing from the spirit and scope ofthe invention. Accordingly, it is not intended that the scope of theclaims appended hereto be limited to the examples and descriptions setforth herein, but rather that the claims be construed as encompassingall of the features of patentable novelty which reside in the presentinvention, including all features which would be treated as equivalentsthereof by those of ordinary skill in the art to which the inventionpertains.

What is claimed is:
 1. A golf ball comprising a layer formed from aheterogeneous composition, the heterogeneous composition comprising: amatrix formed from a thermosetting polymer composition, and discreteparticles of a thermoplastic polymer composition dispersed within thematrix, the thermoplastic polymer composition having a melting pointabove the curing temperature of the thermosetting polymer composition,wherein the particles have a maximum particle size of 0.900 mm.
 2. Thegolf ball of claim 1, wherein the discrete particles are present in thecomposition in an amount of 18 wt % or greater, based on the totalweight of the composition.
 3. The golf ball of claim 1, wherein thediscrete particles are present in the composition in an amount of 20 wt% or greater, based on the total weight of the composition
 4. The golfball of claim 1, wherein the particles have a maximum particle size of0.841 mm.
 5. The golf ball of claim 1, wherein the golf ball comprises acore and a cover, and wherein the cover comprises the layer formed fromthe heterogeneous composition.
 6. The golf ball of claim 1, wherein thegolf ball comprises a core, a cover, and an intermediate layer disposedbetween the core and the cover, wherein the intermediate layer is formedfrom the heterogeneous composition.
 7. A golf ball comprising a layerformed from a heterogeneous composition, the heterogeneous compositioncomprising: a matrix formed from a thermosetting polymer composition,and discrete particles of a thermoplastic polymer composition dispersedwithin the matrix, the thermoplastic composition having a melting pointabove the curing temperature of the thermosetting composition, whereinthe difference in the specific gravity of the thermosetting polymercomposition and the specific gravity of the thermoplastic composition isat least 0.13 g/cm³.
 8. The golf ball of claim 7, wherein the differencein the specific gravity of the thermosetting polymer composition and thespecific gravity of the thermoplastic composition is at least 0.15g/cm³.
 9. The golf ball of claim 7, wherein the discrete particles arepresent in the composition in an amount of 18 wt % or greater, based onthe total weight of the composition.
 10. The golf ball of claim 7,wherein the discrete particles are present in the composition in anamount of 20 wt % or greater, based on the total weight of thecomposition
 11. The golf ball of claim 7, wherein the particles have amaximum particle size of 0.841 mm.
 12. The golf ball of claim 7, whereinthe golf ball comprises a core and a cover, and wherein the covercomprises the layer formed from the heterogeneous composition.
 13. Thegolf ball of claim 7, wherein the golf ball comprises a core, a cover,and an intermediate layer disposed between the core and the cover,wherein the intermediate layer is formed from the heterogeneouscomposition.
 14. A golf ball comprising a layer formed from aheterogeneous composition, the heterogeneous composition comprising: amatrix formed from a thermosetting polymer composition, and discreteparticles of a thermoplastic polymer composition dispersed within thematrix, the thermoplastic composition having a melting point above thecuring temperature of the thermosetting composition, wherein thecomposition comprises at least 500 of the discrete particles.
 15. Thegolf ball of claim 14, wherein the particles have a maximum particlesize of 0.841 mm.
 16. The golf ball of claim 15, wherein the discreteparticles are present in the composition in an amount of 18 wt % orgreater, based on the total weight of the composition.
 17. The golf ballof claim 15, wherein the discrete particles are present in thecomposition in an amount of 20 wt % or greater, based on the totalweight of the composition.
 18. The golf ball of claim 14, wherein thegolf ball comprises a core and a cover, and wherein the cover comprisesthe layer formed from the heterogeneous composition.
 19. The golf ballof claim 14, wherein the golf ball comprises a core, a cover, and anintermediate layer disposed between the core and the cover, wherein theintermediate layer is formed from the heterogeneous composition.
 20. Thegolf ball of claim 14, wherein the difference in the specific gravity ofthe thermosetting polymer composition and the specific gravity of thethermoplastic composition is at least 0.11 g/cm³.
 21. A golf ballcomprising a layer formed from a heterogeneous composition, theheterogeneous composition comprising: a matrix formed from athermosetting polymer composition, and discrete particles of athermoplastic polymer composition dispersed within the matrix, thethermoplastic polymer composition having a melting point above thecuring temperature of the thermosetting polymer composition, wherein theparticles have a maximum particle size of 0.900 mm and are present inthe heterogeneous composition in an amount of 18 wt % or greater, basedon the total weight of the heterogeneous composition, and wherein thedifference in the specific gravity of the thermosetting polymercomposition and the specific gravity of the thermoplastic composition isat least 0.13 g/cm³.
 22. The golf ball of claim 21, wherein thethermosetting matrix composition is selected from the group consistingof ethylene propylene rubbers, ethylene-propylene-diene rubbers,styrene-butadiene rubbers, butyl rubbers, halobutyl rubbers,acrylonitrile butadiene rubbers, polychloroprenes, alkyl acrylaterubbers, chlorinated isoprene rubbers, acrylonitrile chlorinatedisoprene rubbers, polyalkenamers, phenol formaldehydes, melamineformaldehydes, polyepoxides, polyimides, polysiloxanes, alkyds,polyisocyanurates, polycyanurates, polyacrylates, and combinations oftwo or more thereof.
 23. The golf ball of claim 21, wherein thethermoplastic matrix composition is selected from the group consistingof non-ionomeric acid copolymers, polyether amides, polyester amides,polyimides, polystyrenes, polyethylenes, polypropylenes,rubber-toughened polyolefins, styrenic copolymers and styrenic blockcopolymers, dynamically vulcanized elastomers, ethylene vinyl acetates,ethylene (meth)acrylate based polymers, ethylene elastomers, propyleneelastomers, ethylene propylene rubber, ethylene-propylene-diene rubber,polyvinyl chlorides, polytetrafluoroethylene, functionalized derivativesthereof, and combinations of two or more thereof.